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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Demonstrating Advanced Nuclear Energy Solutions for Net Zero

Background/Objectives. The aggressive goals being set by nation states, communities, and private industry for decarbonization of grid electricity, industrial heat sources, and transportation around the world are imperative to mitigating the devastating effects that we are seeing from climate change. Although many of these goals focus on accomplishments by 2035 or 2050, the decisions that we make today won’t just impact the landscape of energy systems for the next 20 or 30 years—they will shape the world’s environment for centuries to come. That means that we can’t just focus on technologies that will get us to 2050, but technologies that will withstand our energy demands over that long-ranging future. Success will require us to utilize all of the clean energy resources that we have available to meet demands for electricity, heat, and steam, and we will need energy carriers such as hydrogen that do not emit additional greenhouse gases at the point of use. Nuclear energy, ranging from technologies in service today to advanced, higher temperature and modular systems that will be in service this decade, will provide a robust complement to renewable energy resources that operate variably. Researchers across the U.S. Department of Energy laboratory complex are working to advance multiple aspects of these clean energy solutions, with many focusing on integrated energy system solutions that leverage all available clean energy assets to meet wide-ranging energy demands. Approach/Activities. Nuclear energy is a proven, zero-emission option during operation that can provide consistent, dispatchable power to meet electricity demands while also providing high-quality heat that can meet energy demands beyond the electricity sector. Energy system design should seek to maximize these assets. As a dispatchable energy source with a small land utilization footprint, nuclear energy can be collocated with renewable resources, and the smaller systems that will be deployed this decade (ranging from a few megawatts to hundreds of megawatts) can be installed right where that energy is needed. Integrated nuclear and renewable systems will enhance power grid reliability and resilience, and they will help stabilize the grid through their increasingly flexible operation. Licensing, installation, and broad adoption of these advanced nuclear energy systems are expected to progress significantly in the 2020s, but this may be longer than desired by some stakeholders wishing to implement impactful clean energy decisions today. However, one must recall that nuclear energy systems will operate for 80 or more years, as is being demonstrated by current fleet nuclear systems. The nuclear community is extremely thorough in reviewing these systems with regard to safety and security; these efforts ensure that the deployed systems will continue to provide reliable, resilient energy over that operational lifetime. That investment of time up front will ensure that we can support energy demands over the centuries to come. While advanced nuclear technologies move through this process, communities and private industry may choose to install renewable generation systems that can later be coupled to the complementary nuclear systems as they become available—thus moving closer to the net zero goals in the near term. Choosing technologies and deployment configurations that allow small modular nuclear powerhouses to be added to these “energy parks” as they become available will ensure that advanced technologies can be readily adopted to support growing demands for clean energy. Results/Lessons Learned. The primary focus of integrated energy systems (IES) research is to assess the technical and economic potential of novel multi-input, multioutput solutions that are expected to enhance energy system flexibility, reliability, and resilience as we pursue a clean energy transition. Various energy applications and product streams beyond electricity are being evaluated, ranging from generation of potable water to production of hydrogen, fertilizers, synthetic fuels, and various chemicals. In early FY23 Idaho National Laboratory (INL) will commission thermal energy generation systems that emulate nuclear fission energy input using electric heating and will allow for integrated system testing with thermal energy storage, hydrogen production via high temperature electrolysis (HTE), and power systems hardware to demonstrate operation of a clean energy park within a microgrid or larger grid infrastructure, supporting up to 450 kW of heat input via electric heating and demonstrating operation of HTE systems at the multi-hundred kW scale. This presentation will highlight the wide array of RD&D being conducted at INL and partner laboratories to develop and deploy nuclear and renewable-based IES that will be key to achieving our net zero goals, including both computational and experimental demonstrations. By working with key collaborators in industry, analytical st

08 HYDROGEN↗
DOE OSTI2025

Benchmarking MELCOR's NAC Package to ABCOVE Test AB7

This report presents analyses of the AB7 ABCOVE sodium spray fire experiment with the MELCOR code. This code simulates the progression of accident events for analysis and auditing purposes of nuclear facilities during accident conditions. Historically, the ABCOVE experiments have contributed to the validation of aerosol physics and related phenomena. Given advancements in sodium-cooled reactor designs, characterization of the sodium spray combustion may further the review and validation of newly incorporated sodium properties and physics packages, namely, the sodium equations of state (EOS) and the sodium combustion (NAC) package within MELCOR. Previously, the AB5 and AB6 experiments were analyzed with and without the NAC package. This work builds on the previous analyses with a demonstration of the current code capabilities of MELCOR with a more mild Na spray and pool fire scenario.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

An approach to combine neutron and ion irradiation data to accelerate material qualification for nuclear reactors

Next-generation nuclear power plants are generally characterized by higher operating temperatures, increased neutron fluences and energies, and distinct corrosive coolant environments versus the existing light water reactor fleet. Whether using existing materials in new environments, newly developed materials tailored for these environments, or new manufacturing methods, the traditional decades-long approach for materials qualification does not facilitate rapid deployment. Ion irradiation has demonstrated success in reproducing material microstructure and select property evolution resulting from neutron irradiation with three to four orders of magnitude reduction in time and cost, making it an ideal candidate for accelerated irradiation testing. Because microstructure has a large impact on bulk material properties, limited neutron irradiation data at lower damage levels can in principle be combined with accelerated ion testing results and modeling and simulation to form an accurate prediction of microstructure evolution and select properties under different neutron irradiation conditions and at higher damage levels. The objective of this work is to present a conceptual framework of specific steps to fulfill several technical challenges associated with qualifying materials for performance in radiation environments on an accelerated time frame. A brief review of the regulatory landscape for materials in nuclear environments is presented, followed by additional overviews to understand the current state of the art for correlation of materials properties across radiation environments using experimental and computational methodologies. Finally, the roles of academia, national laboratories, and industry in the advancement of this accelerated materials qualification framework are discussed as a path forward, with possible case studies presented.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

User Manual for the Thermal Hydraulic Code SE2RCT

SE2-ANL is a modified version of SUPERENERGY-2 which interfaces the power distribution in the ANL maintained physics codes for the user. SE2RCT is a special version of SE2-ANL developed for specific use on models of the Experimental Breeder Reactor-II (EBR-II). SE2RCT fulfills a specific role in the calculated results as part of the Fuels Irradiation and Physics Database (FIPD) and is built to connect with the Physics and Analysis DataBase (PADB) for metallic fuel research and development in advanced sodium-cooled fast reactors (SFRs) created for EBR-II. SE2RCT is primarily a thermal analysis code that interfaces with the RCT based pin power details instead of the built-in pin power dehomogenization strategy in SE2-ANL. Beyond the thermal hydraulic calculation, the SE2RCT code provides detailed axial distributions of the RCT calculated results. SE2RCT also calculates the the axial distribution of pin wise DPA for the cladding materials which is part of the FIPD calculated results. This report serves as the user manual for SE2RCT and thus eliminates the QA gap of missing documentation on the SE2RCT software. All of the features and limitations of SE2RCT are documented in this report. The input and output specifications of SE2RCT are discussed in detail, and some unique features of SE2RCT, e.g. accurate pin power and temperature results for problems with non-uniform composition within an assembly, are also demonstrated and tested.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

A Verification and Validation Approach for COMSOL Multiphysics to Support High Flux Isotope Reactor (HFIR)

Over the last several decades, many reactors have successfully been converted from high enriched uranium (HEU) to low enriched uranium (LEU) fuels in United States in support of its global non-proliferation objectives. Of the reactors slated for conversion, five high-performance research reactors (HPRRs) remain. The high-flux isotope reactor (HFIR) at Oak Ridge National Laboratory (ORNL) is one of the five. Conversion of HFIR requires the qualification of a new fuel. To aid in the conversion process as well as improve safety margins, COMSOL Multiphysics was chosen to support and eventually supplement the steady-state heat-transfer code (SSHTC). In order to use COMSOL as a supplementary tool, i.e. one used for safety basis calculations, the code needs to undergo a verification and validation process. Verification and validation are important processes for the use of any software; however, physics-based solvers have a unique challenge, in that the validation is much more rigorous and its domain is only applicable to the general scope of the problem. This document details the verification and validation of COMOSL for analysis of HFIR. This report is intended for two different users: (1) current and future users of COMSOL for HFIR and (2) for individuals interested in assessing the scope of the validation of COMSOL for HFIR. This report is divided into six sections. The first of which details the process of verification and validation. Section one provides an overview of key concepts from ASME V&V 10, 20, and 40 and how these concepts are used to provide a validation of any multiphysics software. Section two covers the approach needed in order to validate multiphysics software for a given HFIR analysis. Parts three through five split up the key concepts highlighted in section two. The final section provides concluding remarks which demonstrate the scope and limitations of the validation study and how these may be expanded and improved.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Sorbmatech{sup R}Cs, an Innovative Highly Selective Cs Sorbent for Wastewater Decontamination - 20065

The treatment of radioactive wastewater from the operating nuclear industry (energy production, reprocessing of spent fuel, decommissioning of shut-down facilities, etc.) or in case of incidental or accidental situation (such as Fukushima Daichii NPP accident) is an important issue requiring constant improvement of the technologies and techniques used to prevent radioactive releases into the environment and/or to reduce the production of secondary waste. CEA, Orano and CTI are collaborating since 2014, with the support of the French government's program 'investments for the future', to develop Sorbmatech{sup R}Cs, an innovative and patented selective sorbent (Grandjean and Barre 2014) to deal with the removal of radioactive {sup 137}Cs, one of the most hazardous isotope to be managed in nuclear waste, highly efficient either in agitated reactor or in column process. Sorbmatech{sup R}Cs sorbent consists of mesoporous silica particles loaded with potassium-copper hexacyanoferrate nanoparticles (KCu-HCF). This peculiar structure enables much faster sorption kinetics compared to denser crystalline structures, such as Silicotitanate or Zeolite sorbents, whose drawback consists in hindering the diffusion process through the material, and whose larger sorbent particles slow down the ion exchange process. The equilibrium of Sorbmatech{sup R}Cs is reached in few minutes, even at high flow rates in a fixed-bed column process (up to 10 m.h{sup -1} Darcy velocity) with low drop pressure. Moreover, Sorbmatech{sup R}Cs can be used over a wide pH range from 2 to 10 and has a very high selectivity towards {sup 137}Cs even in brine solution (saline, mineral or sea water). This new sorbent also has a K{sub d} higher than 10{sup 5} mL.g{sup -1} depending on the salinity of the wastewater, enabling a highly efficient removal of Cs trace in radioactive wastewater compared to Cs selective sorbent such as Zeolites and Silicotitanates. Its radiological resistance enables the treatment of high, medium and low activity wastewater. The CEA-Orano-CTI/ALSYS partnership leads to the development of a simple and low-cost synthetic route, which demonstrated large-scale manufacturing of the product on a batch of 100 kg. Two products have been developed and are ready for short run market introduction so far with grain size well adapted either for column processes or agitated reactors.. Finally, the industrial implementation has been studied and largely benefits from the properties of the sorbent. Indeed, its high sorption kinetics enable high flow rates resulting in a decrease of operation times, unit sizes, and volumes of secondary waste produced. Moreover, Sorbmatech{sup R}Cs is designed to be combined into a full and integrated solution, ranging from preliminary optimization of operating conditions through numerical dimensioning model, industrial implementation and treatment of the wastewater (through cartridge or preconditioned columns systems developed thanks to Orano's extensive expertise), to long-term stabilization of generated waste (under progress). (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Online Lead/Water Heat Exchanger Sensor/System Feasibility-PNNL (Final Report)

On-line structural health corrosion monitoring in advanced lead fast reactor heat exchangers and molten salt reactor heat exchangers is desirable for detecting tube degradation prior to leaks that may allow mixing of heat exchanger fluids or release of radiological contamination beyond the design containment boundary. This program, On-Line Lead/Water Heat Exchanger Sensor/System Feasibility – PNNL 76092, demonstrates feasibility for an ultrasonic torsional wave mode sensor attached to the outside of a long (30.5-m) heat exchanger tube in the stagnant flow area where the tube joins a heat exchanger plenum and where it is possible to protect a sensor and cable from high-force flows. The sensor must be cable connected to a monitoring instrument near the heat exchanger. The sensor and cable management approach for periodic in-service inspection will be impractical to implement on existing heat exchangers; rather permanently mounted sensors must be installed in conjunction with heat exchanger fabrication. Previous work has shown low-temperature lead zirconate titanate (PZT) piezoceramic sensors are able to detect anomalies of interest in 3.0-m long tubes. These sensors have hereby been extended to a 30.5-m long tube more representative of commercial power heat exchanger designs. The program will continue to investigate higher temperature piezoelectric ceramics and long-term performance of high temperature adhesives and sealants and mechanical pressure coupling for 350-500 °C lead reactor environments and higher temperature (700 °C) molten salt environments.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Development and Evaluation of Embrittlement Resistant Alloys for Advanced LWR Cladding

The primary challenge preventing the deployment of reactor designs that leverage wrought FeCrAl as an advanced light-water reactor (LWR) cladding is irradiation hardening and embrittlement. Wrought FeCrAl alloys experience a loss of post-irradiation ductility and fracture toughness under low-temperature neutron irradiation (< 350°C) resulting from the combined effects of dislocation loop formation and the irradiation-enhanced precipitation of Cr-rich alpha-prime precipitates throughout the microstructure. Over the past decade, significant improvements in our understanding regarding the effect of Cr and Al content have been enabled through neutron irradiations, but even optimized wrought alloys such as C26M remain vulnerable to brittle failure during storage, transportation, and handling following irradiation. This report summarizes multiple irradiation campaigns initiated over the past 7 years and provides recent insights into the effect of (1) minor alloying composition, (2) alloy processing strategy, (3) crystal structure, and (4) the use of advanced oxide dispersion strengthened (ODS) alloys. The first irradiation campaign irradiated body-centered cubic FeCrAl alloy C26M with and without elements such as Mo and Y. It also included face-centered cubic alumina-forming austenitic (AFA) alloys that have a steeper neutronic penalty but that have far superior high-temperature strength than wrought FeCrAl. Finally, this campaign compared conventional wrought C26M with the same material produced using modern powder metallurgical hotisostatic pressing (PM-HIP). The second irradiation campaign, initiated in 2018, irradiated wrought and FeCrAl-ODS materials up to 50 dpa to assess their irradiation resistance to high-doses. The results of this work indicate that wrought C26M suffers significant degradation following neutron irradiation at LWR-relevant temperatures regardless of Mo and Y content. The PM-HIP variant appears to be more resilient to irradiation-induced ductility loss in comparison with wrought variants but still loses almost all ductility by 8 dpa. Notably, the AFAs retained at least 5% total elongation after irradiation at the same dose and temperature condition, although additional deterioration may be expected at higher fluence levels. FeCrAl-ODS materials show the greatest promise as a transformative longer-term accident-tolerant fuel (LT-ATF) cladding material. The extruded 106ZY10C alloy retained 10% total elongation after 16 dpa irradiation and retained 8% total elongation after 50 dpa. Additional challenges with FeCrAl-ODS alloys also remain, including optimization of end cap joining methodologies, enhancement of fracture toughness, scaling production to prove economic viability, and optimizing post-pilger heat treatments to maximize ductility and irradiation resistance. This series of irradiations demonstrates the efficacy of the LWR testbed available within the United States for the rapid irradiation and down-selection of LT-ATF candidates. As the country rapidly accelerates its timeline for the deployment of advanced reactor concepts, the effective utilization of the High Flux Isotope Reactor for separate-effects style irradiations should continue to be prioritized to answer the final questions pertaining to LT-ATF candidates necessary for the deployment of advanced boiling water reactors and small modular reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Advancing Fusion with Machine Learning Research Needs Workshop Report

Abstract Machine learning and artificial intelligence (ML/AI) methods have been used successfully in recent years to solve problems in many areas, including image recognition, unsupervised and supervised classification, game-playing, system identification and prediction, and autonomous vehicle control. Data-driven machine learning methods have also been applied to fusion energy research for over 2 decades, including significant advances in the areas of disruption prediction, surrogate model generation, and experimental planning. The advent of powerful and dedicated computers specialized for large-scale parallel computation, as well as advances in statistical inference algorithms, have greatly enhanced the capabilities of these computational approaches to extract scientific knowledge and bridge gaps between theoretical models and practical implementations. Large-scale commercial success of various ML/AI applications in recent years, including robotics, industrial processes, online image recognition, financial system prediction, and autonomous vehicles, have further demonstrated the potential for data-driven methods to produce dramatic transformations in many fields. These advances, along with the urgency of need to bridge key gaps in knowledge for design and operation of reactors such as ITER, have driven planned expansion of efforts in ML/AI within the US government and around the world. The Department of Energy (DOE) Office of Science programs in Fusion Energy Sciences (FES) and Advanced Scientific Computing Research (ASCR) have organized several activities to identify best strategies and approaches for applying ML/AI methods to fusion energy research. This paper describes the results of a joint FES/ASCR DOE-sponsored Research Needs Workshop on Advancing Fusion with Machine Learning, held April 30–May 2, 2019, in Gaithersburg, MD (full report available at https://science.osti.gov/-/media/fes/pdf/workshop-reports/FES_ASCR_Machine_Learning_Report.pdf ). The workshop drew on broad representation from both FES and ASCR scientific communities, and identified seven Priority Research Opportunities (PRO’s) with high potential for advancing fusion energy. In addition to the PRO topics themselves, the workshop identified research guidelines to maximize the effectiveness of ML/AI methods in fusion energy science, which include focusing on uncertainty quantification, methods for quantifying regions of validity of models and algorithms, and applying highly integrated teams of ML/AI mathematicians, computer scientists, and fusion energy scientists with domain expertise in the relevant areas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

The new ITER baseline, research plan and open R&D issues

A new baseline (NB) has been proposed by the ITER Project to ensure a robust achievement of the Projects’ goals, in view of past challenges including delays incurred due to the Covid-19 pandemic, technical challenges in completing first-of-a-kind components and in nuclear licensing. The NB includes modifications to the configuration of the ITER device and its ancillaries (e.g. change from beryllium to tungsten as first wall material, modification of the heating and current drive mix, etc.) as well as additional testing of components (e.g. toroidal field coils) or phased installation (start with inertially cooled first wall before later installation of the final actively water-cooled components) to minimise operational risks. In the NB, the ITER research plan (IRP) will be divided into three main phases: (a) start of research operation, with 40 MW of ECH and 10 MW of ICH, which will focus on the demonstration of 15 MA operation in L-mode, commissioning of all required systems, including disruption mitigation, and the demonstration of H-mode plasma operation in deuterium; (b) DT-1, with 60–67 MW of ECH, 33 MW of neutral beam injection (NBI) and 10–20 MW of ICH, which will demonstrate robust operation in high confinement H-mode plasmas in DT up to Q ⩾ 10 and for burn durations of 300–500 s within an accumulated neutron fluence of ∼1% of the ITER machine’s lifetime total, and; (c) DT-2, with up to 67 MW of ECH, up to 49.5 MW of NBI and up to 20 MW of ICH, with the ITER tokamak and ancillaries in their final configuration to demonstrate routine operation in DT plasmas at high Q and the Q ⩾ 5 long-pulse and steady-state scenarios to the final neutron fluence and to perform R&D on nuclear fusion reactor issues. The logic, physics basis, modelling and experimental evaluations carried out to support the NB and the associated IRP are described. These include the impact of the tungsten wall on plasma scenarios and associated risk mitigation measures, as well as the optimisation of the tokamak components and ancillaries to minimise Project risks. Open R&D issues related to these evaluations and mitigation measures are also described together with experimental, modelling and validation activities required to address them.

ITER↗
DOE OSTI2026

Achievement of a high-density, high-confinement, and high-beta tokamak plasma regime in DIII-D, and implications for a lower-current path for ITER and FPP

Experiments on DIII-D have demonstrated a density-confinement synergy that enables sustainment of high performance in a previously unattained parameter regime of simultaneous very high energy confinement quality (H 98y2 ≥ 1.5), very high line-average density Greenwald fraction (ƒ Gr = πa 2 < n >/I P ≥ 1.4), and high toroidal beta (β T ≥ 3%). Tokamak operation in this regime is essential for a compact steady-state FPP, as well as for Q=10 with 500 MW of fusion power in ITER at I P << 15 MA. These experiments leveraged the knowledge that, in the high-poloidal-beta (β P ) regime, impurity and density gradients can enhance turbulence stabilization caused by high α MHD (α MHD ~(dβ P )⁄dr). This was described by theoretical predictions and gyrokinetic transport simulations [M.T. Kotschenreuther et al, 2024 Nucl. Fusion, 64 076033], and later confirmed by experiments on DIII-D [S. Ding et al, 2024 Nature 629 555]. To increase both β P and β T , the new experiments increased the ideal-wall stability β N -limit by using a smaller plasma-outer wall distance and higher triangularity in the plasma cross section (top/bottom average δ~0.9), enabled by the recent “shape & volume rise” (SVR) modification to the DIII-D divertor. The higher triangularity also contributed to achieving higher ƒ Gr by enabling higher pedestal density. At high density, the pedestal is ballooning limited and exhibits small and frequent ELMs, while the divertor is near detachment even without any impurity seeding. High plasma performance was attained and sustained reproducibly, with the eventual terminations brought about by an MHD mode destabilized as the current profile slowly continued to evolve. A path to stationary fully noninductive operation might include ECH injection to reduce both core impurity accumulation and the electron collisionality, thus increasing the bootstrap current. These experiments provide the first experimental demonstration of the ƒ Gr , H 98y2 , and β T values required simultaneously for ITER Q = 10 at I P < 10 MA, pointing to practical ways to improve the energy confinement in a fusion reactor.

Garofalo, Andrea M. [General Atomics, San Diego, C↗
DOE OSTI2022

Enhancing Coking Tolerance and Stability of SOFC Anodes Using Atomic Layer Deposition (ALD) of Oxide Thin Films

The overall objective of this project was to use atomic layer deposition (ALD) to add modifiers to the surfaces of conventional Ni-YSZ cermet, solid oxide fuel cell (SOFC) anodes to enhance both their tolerance to hydrocarbon fuels by decreasing their propensity to form coke deposits, and to increase redox stability. Studies of the use of ALD to modify analogous supported metal powder catalysts were also added to the scope of the project in response to our industrial partner, Atrex going out of business. The initial portion of the program focused on designing and building the ALD reactor required for deposition of the oxide modifier films. Studies of the oxide modifier films on the coking tolerance and of redox properties of Ni-cermet anodes were then carried out. These studies demonstrated that while surface oxide modifiers were able to impart some coking resistance this only occurred for a relatively small range of operating conditions (e.g., temperature, steam-to-fuel ratio, etc.) and not at the level that would be required for operating in methane fuel at low steam-to-methane ratios. In light of this observation, we focused on assessing another approach to enhance anode coking resistance which eliminated bulk Ni from the anode. This approach made use of electronically conducting perovskite films to provide electrical conductivity in the anode, while using small amounts of Ni or other metals, such as Pt, deposited using ALD as the anode oxidation catalyst. This approach proved to be quite promising at both imparting coking resistance and redox stability.

03 NATURAL GAS↗
DOE OSTI2022

Manufacturing Supply Chain Development for Modular Solar-Thermochemical Conversion Platform - CRADA 387 (Final Report)

Modular chemical process intensification (MCPI) is an emerging field where chemical processing is performed using small-scale modular equipment instead of conventional large centralized chemical plants. Conventional chemical plants benefit from economies of scale that encourage scale-up to ever larger plants. A goal of MCPI is to develop technology that intensifies processing so that equipment can be dramatically smaller and integrated into modular systems. Scale-up occurs by adding more modules in parallel rather than making the equipment larger. A key concept is that equipment and modules can ultimately be cheaper by leveraging economies of mass production, analogous to the automotive industry, in manufacturing the equipment. This project made significant progress toward this outcome by meeting the RAPID institute metric to reduce equipment cost by 20% for each doubling in manufacturing volume. The MCPI application was thermochemical technology that is being commercialized by STARS Technology Corporation, one of the CRADA partners. The technology converts solar and renewable power to chemical energy to produce renewable hydrogen, fuels, and chemicals. The benefit to the public is reduction in greenhouse gases that are contributing to climate change. The project transitioned the steam methane reforming (SMR) reactor from conventional fabrication methods to additive manufacturing (AM) direct metal laser sintering (DMLS) process. This is projected to reduce the cost of making a reactor by 58% when producing 100 reactors per year. Innovations in the DMLS process produced a patented design that reduces reactor weight by 60%. Reductions in material costs and processing time extend the DMLS advantage to higher production volumes. The new design promises to be 38% cheaper than the conventional processes at 1000 units per year. The resulting 87% reduction in the steam methane reforming (SMR) module cost in scaling from current costs meets the RAPID metric. The project was successful in producing and testing the first ever additively manufactured SMR reactors. A reactor achieved over 82% efficiency in converting electric power to chemical energy, which is a world record for an inductively heated SMR. The project has contributed to the design and assembly of a first demonstration plant that is headed to a hydrogen bus filling station in Thousand Palms, CA.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

CTF Validation and Verification: Version 4.4

Coolant-Boiling in Rod Arrays- Two Fluids (COBRA-TF) is a thermal/hydraulic (T/H) simulation code designed for light water reactor (LWR) analysis. It uses a two-fluid, three-field (i.e., fluid film, fluid drops, and vapor) modeling approach. Both subchannel and 3D Cartesian forms of nine conservation equations are available for LWR modeling. The code was originally developed by Pacific Northwest Laboratory in 1980 and has been used and modified by several institutions over the last several decades. COBRA-TF is also used at the Pennsylvania State University (PSU) by the Reactor Dynamics and Fuel Modeling Group (RDFMG) and has been improved, updated, and subsequently became the CTF. One part of the improvement process includes validating the methods in CTF. This document seeks to provide a certain level of certainty and confidence in the predictive capabilities of the code for the scenarios it was designed to model—rod bundle geometries with operating conditions that are representative of prototypical pressurized water reactor (PWR)s and boiling water reactor (BWR)s in both normal and accident conditions. This is done by modeling a variety of experiments that simulate these scenarios and then presenting a qualitative and quantitative analysis of the results that demonstrates the accuracy to which CTF is capable of capturing specific quantities of interest.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Synergistic Thermo-Microbial-Electrochemical (T-MEC) Approach for Drop-In Fuel Production from Wet Waste

This project successfully developed and demonstrated the synergistic thermo-microbial-electrochemical (T-MEC) process, converting food waste into sustainable biofuels while achieving self-sustaining wastewater treatment and hydrogen production. By integrating hydrothermal liquefaction (HTL) and microbial electrolysis cells (MECs), the project advanced waste-to-fuel technology and expanded the understanding of sustainable waste valorization. It established a scalable framework for achieving high carbon efficiency, effective pollutant removal, and energy recovery, showcasing the potential of combining biological, thermal, and electrochemical systems to optimize resource recovery and reduce environmental impacts. The project demonstrated the technical effectiveness of the T-MEC process, achieving over 50% improvement in carbon efficiency and reducing waste processing costs by more than 25% compared to anaerobic digestion (AD). The HTL pilot reactor processed food waste at 90 kg/h, producing up to 200 L/day of biocrude oil with high conversion efficiency. A critical desalting step in pretreatment prevented catalyst fouling, enabling efficient hydrotreating with 100% deoxygenation and denitrogenation and sulfur reduction to <15 ppm. This positioned the kerosene fraction as a strong candidate for sustainable aviation fuel (SAF). The MECs achieved rapid startup, 86.4% COD removal, and hydrogen production rates of 1.8 L H 2 /L cat /day, among the highest recorded for pilot-scale systems. The integrated process achieved 65% carbon efficiency to biocrude and 58% to finished fuels, outperforming AD's 41% and 33% efficiencies for biogas and natural gas vehicle fuels. System analysis highlighted economic potential, with minimum fuel selling prices (MFSP) decreasing from $\$$25/GGE at 5 tpd to $\$$10/GGE at 500 tpd due to economies of scale. Future work will focus on reducing MEC material and membrane costs, enhancing performance through higher current densities, and creating tailored operational strategies for diverse feedstocks. Optimization of the integrated system will improve scalability and feasibility, positioning the T-MEC process as a competitive solution for converting wet waste into sustainable fuels and clean water. Beyond its technical and economic achievements, the project offers significant public benefits. The T-MEC process provides a sustainable alternative to landfilling and incineration, reducing greenhouse gas emissions and conserving resources. Converting waste into SAF and renewable fuels supports decarbonization in the transportation sector, advancing energy independence and reducing reliance on fossil fuels. Additionally, the process minimizes environmental pollutants, transforming them into valuable products like hydrogen and fuels, contributing to a cleaner and more sustainable future.

09 BIOMASS FUELS↗
NASA NTRS1990

Optimal design of a space power system

The aerospace industry, like many other industries, regularly applies optimization techniques to develop designs which reduce cost, maximize performance, and minimize weight. The desire to minimize weight is of particular importance in space-related products since the costs of launch are directly related to payload weight, and launch vehicle capabilities often limit the allowable weight of a component or system. With these concerns in mind, this paper presents the optimization of a space-based power generation system for minimum mass. The goal of this work is to demonstrate the use of optimization techniques on a realistic and practical engineering system. The power system described uses thermoelectric devices to convert heat into electricity. The heat source for the system is a nuclear reactor. Waste heat is rejected from the system to space by a radiator.

Chun, Young W.↗
DOE OSTI2025

SCM overview & the EBR-II shutdown heat removal tests validation.

Pronghorn is an engineering-scale, coarse-mesh, thermal-hydraulics tool for supporting reactor-core simulations of advanced nuclear reactors. Most of the current efforts in Pronghorn have been devoted in developing porous finite-volume capabilities and adapting closure correlations for coarse-mesh thermal-hydraulics modeling. However, for liquid-metal reactors (LMRs) with wire-wrapped fuel pin assemblies, a pin-level thermal-hydraulic resolution is required for most safety case studies (pin rupture, channel blockage, etc.). For this purpose, a new Subchannel application is developed in MOOSE, which affords the required flow field resolution, while still preserving an engineering-scale approach. This new solver can be natively coupled to Pronghorn and other MOOSE objects to enable full-core, multi-physics, multi-scale engineering studies. This presentation presents the main features of the SCM code and demonstrates a validation case based on the EBR-II SHRT tests.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2021

Gradient-Informed Design Optimization of Select Nuclear Systems

In this work, we present a gradient-informed design optimization of nuclear reactor core components based on neutronics objectives with both continuous and discrete materials. The main argument in favor of using gradient-informed design optimization is that it scales well with increasing dimensionality of the design space. First, a challenge problem with 121 free parameters is solved with a gradient-informed method and then with a genetic algorithm. Then, a challenge problem to optimize the flux profile of a simplified assembly with eight axial zones is solved. Both challenge problems are solved using directly calculated derivatives from Tools for Sensitivity and Uncertainty Analysis Methodology Implementation (TSUNAMI) in the SCALE package. Furthermore, we demonstrate how a discrete optimization problem—selection of materials for 121 voxels—can be lifted into a continuous problem with mixed materials. In the continuous space, adjoint-based gradients are well-defined, and gradient descent is applicable. Then, a forcing function is introduced that with the selection of an appropriately sized hyperparameter can be used to guide the optimized continuous solution back into a discrete solution. This paper presents an account of the challenges that were faced when applying a gradient-informed optimization algorithm using a Monte Carlo calculation to estimate the gradient information and compares a gradient descent optimization method to a genetic algorithm optimization of the same geometry. Overall, this work demonstrates the potential use of adjoint-based gradient calculations in design optimization of nuclear systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗